Polyphosphite stabilizers for polymeric materials



lil wifi liil l Mat w ABSTRACT OF THE DISCLOSURE Polymeric phosphites are prepared by reacting a hydrogenated dihydric phenol or an aromatic dihydric alcohol with a tertiary alkyl, aryl or haloaryl phosphite and stopping the condensation when 50 to 90%, most preferably 65 to 75%, of the theoretical amount of mono-- hydric alcohol or phenol is formed. The most preferred material is that made from hydrogenated bisphenol A. and triphenyl phosphite in which the product obtained has 6.3 to 6.8% phosphorus. The phosphites are useful in stabilizing halogen containing polymers (particularly vinyl chloride resins) and hydrocarbon polymers and are also useful as flame proofing agents for hydrocarbon poly mers, cellulose and cellulose esters.

This application is a division of application 522,395 filed Jan. 24, 1966, now U.S. Patent 3,341,629 and is a continuation-in-part of applications Ser. No. 376,202, filed June 18, 1964, now US. Patent 3,356,770 and Ser. No. 366,891, filed May 12, 1964.

This invention relates to novel phosphite polymers.

In the thermoplastics industry, stabilization of the thermoplastic resins, e.g. polyvinyl chloride and polypropylene, by the use of barium, cadmium, zinc, tin, lead and phosphite systems to prevent degradation from heat, light and weathering has contributed to the rapid growth into markets which were earlier closed to many plastics and has also greatly accelerated the rate of growth in many established areas.

The incorporation of liquid organic phosphates, e.g. see Leistner Patent No. 2,564,646, in stabilizing vinyl chloride resins has given spectacular improvements. However, in many cases the liquids are difiicult or impossible to use and as a result many attempts have been made to prepare the organic phosphite in solid form, preferably as a hard, frangible material that can be easily ground or powdered. These efforts have met with indifferent success in that the solids have been soft, waxy, unctuous, difficult to maintain in finely divided condition and/ or susceptible to rapid hydrolysis.

It is an object of the present invention to make novel. polymeric phosphites.

Another object is to make solid phosphites that can be incorporated into various plastic and elastic compositions as stabilizers.

An additional object is to prepare novel phosphite polymers having improved resistance to hydrolysis.

Still further objects and the entire scope of applicability of the present invention will become apparent from the detailed description given hereinafter; it should be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration Patented Apr. 2, 1968 only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.

It has now been found that the objects can be attained by reacting a trihydrocarbyl phosphite or trihaloaryl phosphite with an aromatic dihydric alcohol or more prefera bIy with a hydrogenated dihydric phenol, i.e. a dihydric alcohol resulting from the hydrogenation of a dihydric phenol (also called a hydrogenated bisphenol).

The reaction is preferably catalyzed with 0.1-5 by Weight of the trihydrocarbyl phosphite of a dialkyl phosphite, a diaryl phosphite, a dihaloaryl phosphite or of an alkaline catalyst such as an alkali metal alcoholate or phenolate. As examples of catalysts there can be used di phenyl phosphite, didecyl phosphite, phenyl decyl phosphite, di(2-methylphenyl)phosphite, di(4-dodecylphenyl) phosphite, di(2-chlorophenyl)phosphite, di(2,4-dimethylphenyDphosphite, di(4-bromophenyl)phosphite, diethyl phosphite, dicyclohexyl phosphite, dioctadecyl phosphite, sodium phenolate, sodium decylate, potassium cresylate, sodium ethylate and sodium octadecanolate. Diphenyl phosphite and similar diaryl phosphites are the preferred catalysts.

It has been proposed previously to prepare polymeric pentaerythritol phosphite esters by reacting diphenyl pentaerythritol diphosphite and the like with a dihydric phenol or dihydric alcohol, Friedman Patent 3,053,878. The compounds of the present invention have superior hydrolytic stability to those of the Friedman patent.

As the trihydrocarbyl or trihaloaryl phosphite reactant there can be used triphenyl phosphite, tris(2-methyl phenyl)phosphife, tris(3-methylphenyl)phosphite, tris(4- methylphenyDphosphite, tris(2 ethylphenyDphosphite, tris(2-isopropylphenyl)phosphite, tris(4 w dodecylphenyl) phosphite, tris(2,4-dimethylphenyl)phosphite, tris(2-ch10 rophenyl)phosphite, tris(Z-bromophenyl)phosphite, tris (Z-fiuorophenyl)phosphite, tris(4 t butylphenyl)phosphite, tris decyl phosphite, tris octyl phosphite, tris(alpha naphthyl)phosphite, dipenyl 4-methylphenyl phosphite. The preferred phosphite reactants are triaryl phosphites, most preferably triphenyl phosphite.

As aromatic dihydric alcohols there can be used p xylylene glycol, m-Xylylene glycol, O-xylylene glycol and 1,4-cyclohexanedimethanol.

As the hydrogenated dihydric phenol there can be used 4,4 -is0propylidene dicylcohexanol (also called bis( 4-hydroxycyclohexyl)dimethyl methane or hydrogenated bisphenol A), di(p-hydroxycyclohexyl)methyl ethyl methane, di(4-hydroxycyc1ohexyl)methane. The preferred dihydric compound is hydrogenated bisphenol A since it gives the best products.

To prepare the compounds of the present invention there are employed 0.5 to 1.5 mols of trihydrocarbyl phosphite or the like per mol of the dihydric compound, e.g. hydrogenated bisphenol-A. Preferably there are used about 2 moles of trihydrocarbyl phosphite for 3 moles of diol, e.g. hydrogenated 'bisphenol A. i

The reaction can be continued until a cross linked or highly branched polymer is formed. Preferably, however, the reaction is stopped while the product is still in the substantially linear or thermoplastic stage. When using the preferred reactants, namely hydrogenated bisphenol A and triphenyl phosphite, the reaction is stopped while the product has 6.36.8% phosphorus by weight. Thus, under the preferred conditions, the reaction is stopped when 65-75% of the theoretical amount of phenol derived from the triphenyl phosphite or the like is removed by distillation.

The reaction can be continued until of the theoretical amount of phenol (i.e. from triphenyl phosphite) has been recovered but this is not preferred since it gives 3 a crosslinked thermosettmg polymer. It is also possible to stop the reaction when only 50% of the theoretical amount of phenol has been recovered but in such case the thermoplastic polymer usually has not advanced to a stage giving optimum properties.

When using triphenyl phosphite and hydrogenated bisphenol A as the reactants, it has been observed that the greater the amount. of phenol removed within the limits of 6.3 to 6.8% phosphorus content in the polymer formed, the less the color of the polymer. If the distillation is continued much beyond the point of 6.8% phosphorus content in the polymer, gel-like, i.e. crosslinked materials, are formed rather than the preferred thermoplastic materials. The reaction is normally carried out with the aid of heat. The reaction can be continued as long as the phenol-by-product is removed. Conveniently the phenol formed is removed by vacuum equivalent to .15 mm. absolute pressure or less.

Linear materials can be formed having the formula I where R 18 the divalent residue of (a) bis-(hydroxyalkyl) benzenes, or (b) the hydrogenated dihydric phenol, and R is aryl, haloaryl or alkyl and n is an integer of 1 or more, e.g., 10, 50 or 200.

Nelson Patent No 2,612,488 shows making phosphite polymers from dihydric phenols. The procedure of Nelson in olving the use of phosphorus trichloride or the like creates problems in obtaining a pure halogen free product, particularly if the reaction is stopped prior to completion. The Nelson procedure also cannot be employed with the cycloaliphatic dihydric alcohols employed in the present invention because the alcohols react with phosphorus trichloride or the like to form organic halides. These in turn can react further to form phosphonates rather than the desired thermoplastic polymeric phosphites.

The products obtained according to the invention are brittle solid resins at room temperature. They can be readily ground for incorporation in an amount of 0.01 to 20% into halogen containing resins, e.g. vinyl chloride resins, as stabilizers against heat and light. They can also be incorporated in an amount of 0.01 to 20% as stabilizers for hydrocarbon polymers such as polyethylene. poly propylene, ethylene-propylene copolymers (e.g. a 50:50 copolymer), polystyrene, acrylonitrile-butadiene-styrene terpolymer. natural rubber. rubbery butadiene-styrene copolymer. polybutadiene. polyisobutylene, isobuty1enebutadiene copolymer( butyl. rubber) and the like. In some instances, it is desirable to also incorporate a phenolic antioxidant such as 2,2-methylene bist4-methyl-6-t-butyl phenol) or 2.4,6-tri-t-butyl phenol.

The products can also be used as antioxidants with barium. cadmium and zinc salts and synergistic activity .has been noted in this connection. Thus there can be included 1-10% of salts such as barium-cadmium. .laurate, zinc stearate cadmium Z-ethylhexoate, barium nonylphenolate, barium octylphenolate, barium stearate, zinc octoate in the antioxidant formulations.

The resins of the present invention can also be m corporated in an amount of l to 50% in other plastic materials to give improved flame and/or fire resistance. Thus they can be used to improve the fire resistance of cellulose, cellulose acetate. cellulose nitrate, cellulose acetate-butyrate. polystyrene, polyethylene, polypropylene and other polymeric monoolefins.

The resins of the present invention are also suitable to form cast or molded articles, e.g. disposable cups.

The initial heating for the reaction is preferably done slowly to avoid an explosion. After initial reaction at about. 100 to 110 C... the reaction mass is heated above 130 e.g'. to 180 C, and then vacuum distilled to emove he bv-product phenol 4 Unless otherwise lndicated, all parts and percentages are by Weight.

Example 1 240 parts of hydrogenated bisphenol A, 341 parts of triphenyl phosphite, 84 parts of t-octylphenol and 6 parts of diphenyl phosphite were mixed and subjected to vacuum distillation until the temperature reached 214 C. with a vacuum of 29.5 inches. 222 parts of distillate were removed. The residue was a solid polymer with a phosphorus content of 7.6%. It was compatible in resins, e.g. polyvinyl chloride, and polypropylene and natural and synthetic rubbers and exerted a stabilizing effect. It was particularly effective in combination with conventional stabilizing systems such as phenols and barium and cadmium soaps.

Example 2 775 parts of a triphenyl phosphite, 480 parts of hydrogenated bisphenol A and 10 parts of diphenyl phosphite were mixed and subjected to vacuum distillation. Terminal conditions were 208 C. and 29.5 inches of vacuum. 363 parts of phenol were removed from the system. The residue was a resinous polymer with a phosphorus content of 8.7%..

Example 3 341 parts of triphenyl phosphite, 240 parts of hydrogenated bisphenol A, and 6 parts of diphenyl phosphite were mixed and subjected to vacuum distillation. Terminal conditions were 216 C. and 29.5 inches of vacuum. The residue was a resinous polymer with a phosphorus content of 8.4%.

Example 4 1860 parts of triphenyl phosphite, 2160 parts of hydrogenated bisphenol A and 24 parts of diphenyl phosphite were mixed and subjected to vacuum distillation as in Example 3. 1112 parts of phenol distillate were removed. The residue was a hard amber-colored resin with a phosphorus content of 6.3%. The product is one of the preferred ones according to the invention and was compatible with and displayed antioxidant activity in stabilizing plastics, e.g. polyvinyl chloride, polyethylene, polypropylene, natural rubber and synthetic rubber. It was particularly effective in plastics when used in combination with conventional barium, zinc and cadmium stabilizers.

Example 5 62 parts of triphenyl phosphite were mixed with 41 parts of pxylylene glycol. The temperature was maintained in the temperature range, to C. for 20 minutes. The glycol dissolved slowly to give a clear viscous liquid. The temperature was then slowly raised to C. and finally to 220 C. The product was finally distilled under 5 mm. Hg pressure at 200 C. The final product was a light colored, brittle solid, at room temperature and has a phosphorus content of 11%.

Example 6 240 parts of hydrogenated bisphenol A, 326 parts of triphenyl phosphite and 4 parts of diphenyl phosphite were mixed and subjected to vacuum distillation". Ter minal conditions were 210 C. and 29.5 inches of vacuum. A total of 170 parts of phenol were removed by the distillation. The product was a hard polymer with a phosphorus content of 8.1%.

Example 7 341 parts of triphenyl phosphite, parts of 1,4-cyclohexanedimethanol and 6 parts of diphenyl phosphite were mixed and subjected to vacuum distillation. Terminal conditions were 158 C. and 5 mm. Hg absolute pressure. 210 parts of distillate were removed. The product was a clear white solid resinous polymer with a phosphorus content o 1.2%.

Example 8 2160 parts of hydrogenated bisphenol A, 1860 parts of triphenyl phosphite and 24 parts of diphenyl pl rpsphite were mixed and subjected to vacuum distillation. Terminal having a molecular weight of 1834, phosphorus content 7 conditions were 205 C. and 29.5 inches of vacuum. 1140 parts of distillate were removed. The still residuegwas a clear solid resin "with a phosphorus content of 6.4%. This product is one of the preferred ones according to the invention.

having a molecular weight of 2704, phosphorus content of 6.8% and hydroxyl number of 82.

The following tabl summarizes the products obtained by reacting TPP with HBPA in the ratio of 2 mols to 3 mols:

As indicated a preferred series of solid phosphite resins TABLE 1 Phenol Out Molecular Hydroxyl Triads, 'n (Mols) Wt. pt Pv Atoms] P,

Polymer Molecule Percent Groups] No. Total Per 11 Molecule 4 4 964 2 6. 4 2 116 9 4. 5 1,834 4 6. 7 3 91 14 4. 67 2, 704 6 6. 8 4 82 19 4. 3, 574 8 6. 9 6 79 24 4. 4, 444 10 7. 0 6 76 29 4. 83 5, 314 12 7. 0 7 74 34 4. 6, 184 14 7. 03 8 72. 8 39 4. 86 7, 064 16 7. 03 9 71. 6 44 4. 88 7, 924 18 7. 04 10 70. 8 49 4. 89 8, 794 20 7. 05 11 70. 2 54 4. 91 9, 664 22 7. 05 12 69. 7 59 4. 91 10, 534 24 7. 05 13 69. 2 17 84 4. 94 884 34 7.1 18 67. 9 Cross linked 6. 0 7. 98 0 0 Example 9 or polymers is prepared from triphenyl phosphite and hydrogenated bisphenol A in which the reactants are used in the molecular proportions to provide equal mols of replaceable phenol and hydroxyl groups, i.e. 2 mols'of triphenyl phosphite (TPP) and 3 mols of hydrogenated bisphenol A (HBPA).

Varying amounts of phenol are removed from this system to provide increased phosphorus content, increased molecular weights and decreased amounts of free bydroxyl groups. Thus, by reacting the 2 mols of TPP with 3 mols of HBPA anti stripping out 4 mols of phenol there is formed a first polymer unit which has the following formula The procedure of Example 8 was repeated but the distillation was continued until 1271 parts of distillate were collected. The still residue was a clear solid resin with a phosphorus coiltent of 6.7%. This product is one of the preferred ones acco-rding to the invention.

Example 11 1 part of the resin prepared in Example 4 was mixed with parts of vinyl chloride resin (Geon 103 Ep) to give a stabilized composition.

Example 12 2 parts of the resin of Example 4 were mixed with 100 parts of solid polypropylene (melt index 0.8).

CH CH3 $113 1H (B CH3 (l CH3 7 8 Example 13 where R is the divalent residue of a member ot the group consisting of (a) bis(hydroxyalkyl)benzenes and (b) hydrogenated dihydric phenols, R is selected from the group consisting of aryl, alkyl and haloaryl and n is an 1 part of the resin prepared in Example 8 and 2 parts of barium-cadmium laurate were mixed with 100 parts of polyvinyl chloride and 50 parts of dioctyl phthalate 5 integer to give a Stablhzed product" 2. A mixture according to claim 1 where n is 2.

Example 14 3. A mixture according to claim 2 wherein said polyrner member is a vinyl chloride resin and the phosphorus 1 Part of the Product of Example 9 was mlxed Wlth containing material is present in an amount sufficient. to 100 parts of polypropylene (melt index 0.4)., Stabilize the vinyl chloride resin 4. A mixture according to claim 1 wherein n is 2 and Example said polymer member is a member of the group consisting 1 part of the resin prepared in Example 8 and 2 parts of monoolefin polymers, polymers of diolefins having 4 of barium-cadmium laurate were mixed with 100 parts to 5 carbon atoms, and polystyrene, of a vinyl chloride-acrylonitrile copolymer (60:40, 15 5, Av mixture according to claim 2 wherein the phos- Dynel), phorous containing material has the formula.

In place of the vinyl chloride resins mentioned above and, said polymer member is a vinyl chloride resin and there can be stabilized other halogen containing polythe phosphorus containing material is present in an mers such as chlorinated polyethylene having 14 to 75%, amount sutficient to stabilize said resin,

e.g. 27% chlorine by weight, polyvinyl chloride, poly- 6. A mixture according to claim 1 wherein n is 2, the vinylidene chloride, polyvinyl bromide, polyvinyl fiuophosphorus containing material has the formula ride, copoiymers of vinyl chloride with 1 to 90%, pre and said polymer member is a member of the group ferably 1 to of a coplymerizable ethylenically unconsisting of monoolefin polymers, polymers of diolefins saturated material such as vinyl acetate, vinyl butyrate, having4 to 5 carbon atoms, and polystyrene. vinyl benzoate, allyl acetate, vinyl sterate, vinylidene 7 A mixture according to claim 1 wherein n is 2, fluoride, diethyl fumarate, diethyl maleate and other R is aryl and said polymer member is a vinyl chloride alkyl fumarates and maleates, vinyl propionate, methyl resin and the phosphorus containing material is present acrylate, ethyl ecrylate, butyl acrylate, 2-ethylhexyl in an amount sutficien-t to stabilize said resin, acrylate and other alkyl acrylates, methyl methacrylate, 8. A mixture according to claim 1 wherein n is 2, R ethyl methacrylate, butyl methacrylate and other alkyl is aryl and said polymer member is a member of the methacrylates, methyl alpha chloroacrylate, styrene, group consisting of monoolefin polymers, polymers of alpha methyl styrene, trichloroetliylene, vinyl ethers diolefins having 4 to 5 carbon atoms, and polystyrene, such as vinyl ethyl ether, vinyl chloroethyl ether, vinyl 9 A polymer member of the group consisting oi": a phenyl ether, vinyl ketones such as 'vinyl methyl ketone vinyl halide polymer, a vinylidene halide polymer, chloriand vinyl phenyl ketone, l-fluorol -chloroethylene, nated polyethylene, monoolefin polymers, polymers of acrylonitrile, chloroacrylonitrile, allylidene diacetate, and diolefins having 4 to 5 carbon atoms, polystyrene, cel chloroallylidene diacetate, Typical copolymers include lulose, cellulose acetate, cellulose acetate-butyrate and vinyl chloride-vinyl acetate (96:4 sold commercially cellulose nitrate admixed with a branched phosphorus VYNW), vinyl chloride-vinyl acetate (87:13), vinyl containing polymer having the formula chloride-vinyl acetate-maleic anhydride (86:l3:l), vinyl HOROPOROPOROH -chloride-diethyl fumarate (95:5) vinyl chloride-trichloro- I ethylene (95:5), vinyl chloride-Z-ethylhexyl acrylate 0 (8%0) and yinyl chloride-acrylonitrile (60:40), (ROPOROPOROH)m at is claimed is; 5 l. A polymer member of the group consisting of a 0 g vinyl halide polymer, a vinylidene halide polymer, chlorii I nated polyethylene, monoolefin. polymers, polymers of di- ROIFOBOPOROH olefins having 4 to 5 carbon atoms, polystyrene, cellulose, 0 cellulose acetate, cellulose acetate-butyrate and cellulose R1 R1 nitrate, admixed with a thflmoplasiic PhQSPhOFUS where R is the divalent residue of a member of the group mining at a having the basic Structure consisting of (a) bis(hydroxyalkyl)benzenes and (b) moaoi monon hydrogenated dihydric phenols, R is selected from. the

F group consisting of aryl, alkyl and haloaryl and m is an R, integer of at least zero,

10, A mixture according to claim 9 wherein R is aryL 11, A mixture according to claim 9 where m is zero.

12. A mixture according to claim 11. wherein said plastic member is a vinyl chloride resin and. the phos' phorus containing polymer is present in an amount sufii cient to stabilize the vinyl chloride resin;

13L A mixture according to claim 12 wherein R. is the residue ofv 4,4-isopropylidene dicyclohexano'l,

14: A mixture according to claim. 13 wherein R is aryl of the phenyl series.

15, A mixture according to claim 14 wherein. R is phenyl= 16, A mixture according to claim 9 wherein m: is zero and said polymer member is a member of the group con sisting of monoolefin polymers, polymers of diolefins having 4 to 5 carbon atoms, and polystyrene.

17, .A mixture according to claim 16 wherein R is the residue of 4,4-isopropylidene dicyclohexanol,

18, A mixture according to claim 17 wherein R is aryl of the phenyl series.

19,, A mixture according to claim 9 where m is 1,

20 A mixture according to claim 19 wherein said polymer member is a vinyl chloride resin and the phosphorus containing polymer is present in an amount suffi. cient to stabilize the vinyl. chloride resin,

21, A mixture according to claim 20 wherein. R. is the residue of 4,4'-isopropylidene dicyclo'hexanol,

22, A mixture according to claim 21 wherein R is aryl of the phenyl. series having up to one alkyl. group attached to the phenyl. nucleus 23, A. mixture according to claim. 22 wherein R phenv't :24, .A. mixture according to claim 9 wherein said polymer member is a member of the group consisting of monoolefin polymers, polymers of diolefins having 4 to 5 carbon atoms, and polystyrene.

25, A mixture according to claim. 24 wherein R. is the residue of 4,4-isopropy1idene dicyclohexanol.

26, A mixture according to claim 25 wherein R is aryl of the phenyl series,

27. A polymer member of the group consisting of a vinyl halide polymer, a vinylidene halide polymer, chlorinated polyethylene, monoolefin polymers, polymers of diolefins having 4 to 5 carbon atoms, and polystyrene admixed with a thermoplastic trivalent phosphorus containing material having as the sole substituents attached to the phosphorus OROH and -OR where- R is the divalent residue of either a bis(hydroxyalkyl)benzene or hydrogenated dihydric phenol and R is either aryl, alkyl or haloaryl, there being at least one R and at least one R, in the molecule:

References Cited UNITED STATES PATENTS 2,612,488 9/1952 Nelson 260-47 3,341,629 9/1967 Larrison M 260-897 FOREIGN PATENTS 978,285 12/ 1964 Great Britain MURRAY TILLMAN, Primary Examiner,

Jl WHITE, Assistant Examiner. 

